Specifications

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Maintenance of Pleasureboat Diesel Engine

GM Series

1.Safety Precaution for Inspection

1) Battery Fluid

Battery fluid is diluted sulfuric acid. It can blind you if it gets in your eyes, or burn your skin. Keep the

fluid away from your body. Wash it off immediately with a large quantity of fresh water if you get any

on you.

2) Fire due to Electric Short-Circuits

Always turn off the battery switch or detach the earth cable(-) before inspecting the electrical system.

Failure to do so could cause short-circuiting and fires.

3) Precautions for Moving Parts

Stop the engine before you service it. If you must inspect while the engine is operating, never touch

moving parts. Keep your body and clothing well clear of all moving parts as this could result in injury.

4) Precautions for Removing Hot Oil and Water to Prevent Burns

If extracting oil from the engine while it is still hot, do not let the oil splash on you.

Wait until the temperature has dropped before removing cooling water from the engine to avoid getting

scalded.

5) Burns from Contact with Hot Engine Parts

The whole engine is hot during operation and immediately after stopping.

The turbocharger, exhaust manifold, exhaust pipe, and engine are very hot.

Never touch these parts with your body or clothing.

6) Burns from Scalding

Never remove the filler cap of the fresh water cooler while the engine is still hot. Stream and hot

water will spurt out and seriously burn you. Wait until the water temperature has dropped, then

wrap a cloth around the cap and loosen it slowly.

After inspection, refasten the filler cap firmly. If the cap is not secure, steam or scalding water

may be emitted during operation causing burns.

2.Engine Specifications

Type Vertical water-cooled 4-cycle diesel engine

Engine Model 1GM10 2GM20(F) 3GM30(F)

Number of cylinders 1 2 3

Cont. rating output

5.9kW(8PS)/3400min-

11.8kW(16PS)/3400min-

17.7kW(24PS)/3400min-

Max. output

6.6kW(9PS)/3600min-

13.2kW(18PS)/3600min-

19.9kW(27PS)/3600min-

Lube oil

capacity

Engine

oil

1.3L 2.0L 2.7L

Clutch oil

0.25L 0.25L 0.3L

3.Fuel oil, lube oil and cooling water

3.1 fuel oil

Summary of content (10 pages)

PAGE 1
Maintenance of Pleasureboat Diesel Engine GM Series 1.Safety Precaution for Inspection 1) Battery Fluid Battery fluid is diluted sulfuric acid. It can blind you if it gets in your eyes, or burn your skin. Keep the fluid away from your body. Wash it off immediately with a large quantity of fresh water if you get any on you. 2) Fire due to Electric Short-Circuits Always turn off the battery switch or detach the earth cable(-) before inspecting the electrical system.
PAGE 2
1) 1) Selection of fuel oil Use the following diesel fuels or equivalents. Select fuels of a higher quality for best engine performance. [Diesel fuel standard for various countries] ISO 8217 DMA ASTM D975 Grade No.1-D or No.2-D JIS K2204 Grade No.2, No.3 or special-No.3 BS 2869 Part-1 class-A1 or A2 At low temperatures, fuel oil becomes difficult to ignite and will not flow easily, making starting difficult.
PAGE 3
4.Maintenance and Inspection 4.1 Fuel Oil System 4.1.1 4.1.1 Checking and Supplying Fuel Oil Check the fuel level inside the fuel tank and supply with the recommended fuel if necessary. Inspection • • daily (before starting) 4.1.2 Draining the fuel tank 1. Put a pan under the drain to catch the fuel. 2. Loosen the drain cock at the bottom of the fuel tank, and drain off any water and dirt collected inside. 3.
PAGE 4
.2.2 Check and supply of Marine gear oil 1. Check the marine gear oil level with the oil dipstick. 2. Supply with the recommended oil if necessary. Check the oil level with the dipstick while to the upper mark. Inspection • • daily (before starting) 4.2.3 Replacing the Engine Lube Oil and Lube Oil Filters 1. Drain off the lube oil. It is easier and more effective to drain the engine lube oil while the engine is still warm after operation.
PAGE 5
4.2.4 Replacing the Marine Gear Lube Oil Replace the lube oil in the marine gear by using the procedure described above. Replace first • • after initial 50 hours second time • • every 250 hours thereafter • • every 1000 hours 4.3 Cooling Water System 4.3.1 Check and supply of cooling water 1. Check the cooling water level in the sub-tank. If the water level is close to the lower limit, remove the sub tank cap and fill with fresh water to the upper limit. 2.
PAGE 6
4.3.2 Checking discharged from the seawater outlet pipe Check that sufficient cooling water is discharged from the seawater outlet pipe. Operation with too little seawater discharge will burn the impeller of the seawater pump. If seawater discharge is too small, stop the engine immediately, identify the cause and repair. Is the Kingston cock open Is the inlet of the Kingston cock clogged Is the sea water suction hose broken, or does the hose suck in air due to a loose joint 4.3.
PAGE 7
Replace the anti-corrosive zinc when it has been reduced to less than 1/2 of its original size. If there is only a little bit of wear, clean the surface by sanding off any corroded areas. 5. Replace plug. 6. Open the Kingston cock and check water leakage. Inspection • • every 500 hours. 4.4 Inspection of the Electrical Parts 4.4.1 Inspection of Battery Check the level of fluid in the battery.
PAGE 8
The remote control handles and the engine control levers are connected by an accelerator cable. Over time the cable becomes stretched and the connections loose causing deviation in the position, which makes operation unsafe. Inspect the cable periodically and adjust if necessary. 1. Adjusting the Governor Remote Control Handle Check to see that the speed lever on the engine side is touching the high speed limiting bolt when the governor handle is put in H ( High Speed ).
PAGE 9
Firing order Suction Exhaust Injection timing (FID) Injection pressure Lubricant pressure Valve clearance - • • • • Mpa Mpa 5.2 List of tightening torques Engine Model Cylinder head Injection nozzle Connecting rod 1-2-1 1-3-4-2-1 0.2±0.03 0.2±0.03 bTDC 15°±1 bTDC 15°±1 bTDC 18°±1 19.6±0.49 (200±5kg/cm2) 0.39±0.05 (4.0±0.5kg/cm2) 1GM10 2GM20(F) 3GM30(F) Main nut and bolts 117.7(12.0 kgf-m) 73.5 N-m (7.5 kgf-m) Auxiliary bolts 29.4(3.0 kgf-m) N-m 19.6(2.0 kgf-m) N-m 24.5(2.5 kgf-m) 6.
PAGE 10
Exhaust Alarm Lamp goes on Faulty Alarm Device Damaged cooling seawater pump Check seawater pump impeller. NOTICE Do not operate the engine if alarm devices are not working properly. Serious accidents may result if difficulties are not spotted due to faulty alarm lamps. Before starting when switch is turned from OFF ! ON, alarm devices do not work. Circuit broken or buzzer Alarm buzzer does not sound. Ask for repairs. damaged. Some alarm lamps do not light up. Circuit broken or lamp burnt out.